Active grille multi part modular frame

ABSTRACT

An active grille shutter arrangement having a modular frame. The active grille shutter arrangement includes a primary frame piece defining a width and height of an aperture of the modular frame, wherein in the primary frame piece has a motor housing, and upper frame portion having a first end and a second end, a lower frame portion having a first end and a second end and the motor housing extends between the upper frame portion and the lower frame portion. There is a plurality of secondary frame pieces. The modular frame of the active grille shutter arrangement is formed by the connection of the primary frame piece in the secondary frame piece, wherein the modular frame defines the aperture.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-Part of U.S. patent applicationSer. No. 14/422,923, Filed Feb. 20, 2015 which is a 371 of InternationalApplication No. PCT/US2013/057572, Filed on Aug. 20, 2013 which claimsthe benefit of U.S. Provisional Application No. 61/695,489, Filed onAug. 31, 2012.

FIELD OF THE INVENTION

The present invention relates to a multi piece modular frame for use inan active grille shutter system for a vehicle.

BACKGROUND OF THE INVENTION

Various attempts have been made to optimize the cooling of variousautomobile parts. Some of the various devices developed have beendesigned to control the air flow throughout the engine compartment ofthe automobile such that the desired amount of heat is transferred awayfrom the engine, transmission, and other components which generate heat,in order to maintain an optimal operating temperature.

However, it is also desirable to bring the engine up to the normaloperating temperature as soon as possible after engine start-up. Whenthe engine is substantially the same temperature as the surroundingenvironment and is turned on, the engine is the least fuel efficient(especially during start-up and the temperature of the surroundingenvironment is cold). The reduced fuel efficiency is why it isconsidered desirable to bring the engine up to the optimal operatingtemperature very quickly. Under these conditions, it is not desirable toremove heat away from the engine and the various components surroundingthe engine, and therefore devices designed to control air flow aroundthe engine are more beneficially used if they do not remove heat awayfrom the engine at start-up.

Active grille systems that have been developed implement a frame istypically molded as a complete part. During assembly, the frame and/orthe vanes have to be distorted in order to assemble the complete systemonto the one piece frame. Additionally, the one piece frame has a lowshipping density as it is mostly empty space. Furthermore, if an activegrille system has two variants with either additional vanes or a baseair flow, a complete new frame must be molded and shipped. It istherefore desirable to provide a frame that is multiple separate moldedparts instead of one complete molding. This will aid in the assembly ofthe active grille shutter system without having to distort the frames orthe vanes. Additionally, having multiple components accommodates thevarious variants that can be needed depending on the particularapplication. Lastly, having a multi-piece frame increases the shippingdensity since the various components can be stacked more closelytogether.

SUMMARY OF THE INVENTION

The present invention is directed to an active grille shutterarrangement having a modular frame. The active grille shutterarrangement includes a primary frame piece defining a width and heightof an aperture of the modular frame, wherein in the primary frame piecehas a motor housing, and upper frame portion having a first end and asecond end, a lower frame portion having a first end and a second endand the motor housing extends between the upper frame portion and thelower frame portion. There is a plurality of secondary frame piecesincluding a first end cap, connectable to the first respective end ofthe upper frame portion and the first end of the lower frame portion byan upper bar and joint formed on the first end of the upper frameportion and a lower bar and joint formed on the first end of the lowerframe portion. A second end of the plurality of secondary frame piecesis connectable to both the second end of the upper frame portion and thesecond end of the lower frame portion by an upper bar and joint formedon the second end of the upper frame portion and a lower bar and jointformed on the second end of the lower frame portion. The modular frameof the active grille shutter arrangement is formed by the connection ofthe primary frame piece in the secondary frame piece, where in themodular frame defines the aperture. The active grille shutterarrangement further includes a plurality of vanes rotatably positionedbetween the first end cap and the second end cap for controlling theamount of air flowing through the one or more apertures of the modularframe. The motor housing of the frame piece extends between the upperframe portion and the lower frame portion.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is an exploded angled perspective view of an active grilleshutter arrangement in accordance with the present invention;

FIG. 2A is an angled perspective view of the active grille arrangementin accordance with the present invention;

FIG. 2B is an angled perspective view of the active grille arrangementin accordance with another aspect of the present invention;

FIG. 2C is an angled perspective view of the active grille arrangementin accordance with another aspect of the present invention;

FIG. 3A is a front angled perspective view of the active grillearrangement in accordance with the present invention;

FIG. 3B is a rear angled perspective view of the active grillearrangement in accordance with the present invention;

FIG. 4 is an exploded rear perspective view of the modular frame inaccordance with an alternate embodiment of the present invention;

FIG. 5 is an enlarged perspective view of an end joint of the upperframe portion;

FIG. 6 is an enlarged perspective view of the assembled end joint andend cap joint in accordance with the present invention;

FIG. 7A is an exploded perspective angled view of an interlockingdovetail joint on the upper frame portion with the upper portion of themotor housing exploded from the interlocking dovetail joint;

FIG. 7B is an enlarged perspective view of the motor housing assembledto the interlocking dovetail joint of the upper frame portion;

FIG. 8A is a perspective view showing the assembly of the modular frame;

FIG. 8B is a perspective view showing the assembly of the modular frame;

FIG. 8C is a perspective view showing the assembly of the modular frame;

FIG. 8D is a perspective view showing the assembly of the modular frame;

FIG. 9 is an exploded perspective view of a third embodiment of theinvention;

FIG. 10 is an exploded perspective view of a fourth embodiment of theinvention;

FIG. 11 is an exploded perspective view of a fifth embodiment of theinvention;

FIG. 12 is an exploded perspective view of a sixth embodiment of theinvention;

FIG. 13 is an exploded perspective view of a seventh embodiment of theinvention including an alternate method of assembly; and

FIG. 14 is an exploded perspective view of an eighth embodiment of theinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring now to the figures generally and with reference to FIGS. 1-8D,an active grille shutter arrangement 10 having an modular frame 12, 112,212, 412, 512, 612 is depicted. The active grille shutter arrangement isdefined herein to be an modular frame 12, 112, 212, 412, 512, 612, inaccordance with one of the embodiments below, along with a motorassembly and vane as described below. Modular frame 12, 112, 212, 412,512, 612, which is shown in various views as being exploded,disassembled and assembled in other views. Referring to FIG. 4 anexploded view of the modular frame in accordance with one embodiment ofthe invention is shown. The modular frame includes an upper frameportion 14 having a first end 16 and second end 18, as well as a lowerframe portion 20 having a first end 22 and second end 24; a first endcap 26 and second end cap 28. The first end cap 26 and second end cap 28are connected to the upper frame portion 14 and lower frame portion 20to form the modular frame 12. As shown in the drawings, the shape of themodular frame 12 is generally rectangular; however, it is possible forthe structure to have different shapes depending upon the particularapplication. The upper frame portion 14, lower frame portion 20, firstend cap 26 and second end cap 28 are all formed of polymeric materialand in a preferred embodiment of the invention are created usinginjection molding. In order to strengthen these components, structuralribs 30 are present on the components in order to make them stronger andreduce the amount of polymeric material needed to create the specificcomponent.

When the upper frame portion 14, lower frame 20, first end cap 26 andsecond end cap 28 are assembled together to form the modular frame 12,one or more apertures, which in the present embodiment of the inventionis a first aperture 32 and second aperture 32′ created to allow air topass through the modular frame 12 when assembled to a vehicle. Theactive grille shutter arrangement 10 is created when the assemblemodular frame 12 has a plurality of vanes 34 connected between the firstend cap 26 and second end cap 28, which can be rotated in order tocontrol the amount of air flowing through the apertures 32. As shown inthe present invention, the vanes 34 are connected between a motorhousing or motor housing 36 extends between the upper frame portion 14and the lower frame portion 20. The vanes 34 are connected between themotor housing 36 and one of the first end caps 26 or second end cap 28and are configured to rotate about barrels 38 formed on each end of theplurality of vanes 34, such that the barrels 38 are rotatably disposedin holes 40 on the motor housing 36, first end cap 26 or second end cap28. Inside of the motor housing 36 is a motor or actuator 42 thatcontrols the rotatable position of the vanes 34 and thereby controls theamount of air flowing through the apertures 32.

The motor housing 36 is has an upper end 44 that connects to an upperframe center joint 46 of the upper frame portion 14. A lower end 48 ofthe motor housing 36 connects to a lower frame center joint 50 formed onthe lower frame portion 20. The connection between both the upper end44, upper frame center joint 46, lower end 48 and lower frames centerjoint 50 can be any type of suitable connection; however, the presentinvention provides an interlocking dovetail joint 52, which is bestshown in FIGS. 8a and 8n . Each interlocking dovetail joint 52 has aprotrusion 54 capable of sliding into a groove 56 for aligning andlocking the motor housing 36 to its respective upper frame portion 14 orlower frame portion 20. In order to lock the motor housing 36 togetherwith the upper frame portion 14 and lower frame portion 20. Eachinterlocking dovetail joint 52 also has a tab with a boss and fastenerarrangement 58 for locking the interlocking dovetail joint 52 in place.It is within the scope of this invention for some type of locking tab orother molded locking mechanism to be used instead of the tab, boss andfastener arrangement 58.

Referring to FIGS. 2A, 2B, 2C and 4, another aspect of the invention isshown that includes a modular frame kit 13 (shown in FIG. 4), includingparts of varying sizes used to create different modular frames. Themodular frame 12 is a first modular frame having a different height andwidth from a second modular frame 12′ or third modular frame 12″. Thefirst modular frame 12, second modular frame 12′ and third modular frame12″ are created by using the different alternate parts shown in FIGS.2A, 2B, 2C and 4, which include the upper frame portion 14, that is afirst upper frame portion, a second upper frame portion 14′, third upperframe portion 14″, the second lower frame portion 20 that is a firstlower frame portion, a second lower frame portion 20′, third lower frameportion 20″, vanes 34, that are a first vanes, second vanes 34′ andthird vanes 34″ (shown in FIGS. 2A, 2B and 2C) all of which havingdifferent widths. The modular frame kit 13 further includes end caps 26,28 that are a first set of end caps, a second set of end caps 26′, 28′and a third set of end caps 26″, 28″ each having different heights. Alsothe modular frame kit 13 includes the motor housing 36, which is a firstmotor housing, second motor housing 36′ and third motor housing 36″ eachhaving a different height and can be interchanged with the other partsof the modular frame kit to form the first modular frame 12, secondmodular frame 12′, third modular frame 12″ as shown in FIGS. 2A-2C.During assembly one upper frame portion, one lower frame portion, onemotor housing and one set of end caps is selected to create a desiredmodular frame construction. The selected one of the set of end caps isconnected to respective opposing ends of the one selected upper frameportion and one selected lower frame portion forming a generallyrectangular or square frame. The one selected motor housing is connectedbetween the one selected upper frame portion and the one selected lowerframe portion.

It is also within the scope of this invention for the parts of themodular frame kit 13 to be used in other combinations to create othermodular frame constructions having a height, width and shape that willvary depending on the different components used. It is further withinthe scope of this invention for the modular frame kit to have a greateror lesser number of alternate components having different dimensions andis not limited to just three alternative parts.

The modular frame kit 13 provides a great deal of versatility for thevarious components since the modular frames 12, 12′, 12″ can have adifferent size assembled from parts having different lengths. Thisallows the modular frame 12, 12′, 12″ to be used with various variantsencountered in and incorporating active grille shutter arrangements onvehicles. This also increases the shipping density of the components ofthe modular frame 12, 12′, 12″ by allowing similar parts to be packagedtogether more tightly than would be possible with a modular frame thatis one piece.

Referring now to FIGS. 5 and 6, the connection between the first andsecond ends 16, 18 of the upper frame portion and the first and secondends of the lower frame portion 22, 24 with each respective first endcap 26 and second end cap 28 are shown. The first end 16 of the upperframe portion 14 has an upper bar end joint 60 formed thereon which isconfigured to slide into an upper bar end cap joint 62 formed on thefirst end cap 26. The first end 22 of the lower frame portion 20 has alower bar end joint 64 formed thereon which slides into a lower bar endcap joint 66 of the first end cap 26. Similarly, the second end 18 ofthe upper frame portion 14 has an upper bar end joint 68 formed thereonand the second end 24 of the lower frame portion 20 has a lower bar endjoint 70 formed thereon. The upper bar end joint 68 of the second end 18of the upper frame portion 14 is configured to slide into an upper barend cap joint 72 of the second end cap 28. Also, the lower bar end joint70 on the second end 24 of the lower frame portion 20 slides into thelower bar end cap joint 74 of the second end cap 28. Once the upperframe portion 14 and lower frame portion 20 are connected to the firstend cap 26 and second end cap 28 as described above, the modular frame12 is complete.

Referring again to FIGS. 5 and 6, is an exploded exemplary view of theconnection between a respective one of the upper bar end joint 60, 68 orlower bar end joint 64, 70 with the respective upper bar end cap joints62, 72 or lower bar end cap joints 66, 74. The upper bar end joint 60,68 and lower bar end joint 64, 70 have show a protrusion that isconfigured to slide into a housing for receiving the protrusion as shownat the upper bar end cap joint 62, 72 and lower bar end cap joint 66,74. In order to lock all the pieces together, an end cap snap tab 76 isused to lockingly receive a frame bar snap post 78. While the drawingsof the present invention show the end cap snap tabs 76 as being formedon the lower bar end cap joint 66, 74 or upper bar end cap joint 62, 72and the frame bar snap post 78 being formed on the upper bar end joint60, 68 or lower bar end joint 64, 70, it is within the scope of theinvention for the end cap snap tab 76 and frame bar snap post 78 to bereversed and on opposing structures. Additionally, it is possible forother suitable injection molded locking mechanisms to be used includingtongue in groove type locks, as well as the use of adhesive ormechanical fasteners depending upon the needs of a particularapplication.

Referring now to FIGS. 1 and 3-8D, once the active grille shutterarrangement 10 has been fully assembled, the arrangement can beconnected to a vehicle using body mounts 80 which are holes used forconnecting the modular frame 12 using fasteners. However, it is possiblefor other types of connection mechanisms to be used such as adhesives,welding or other needs depending on a particular application. It is alsowithin the scope of this invention for the active grille shutterarrangement 10 to be connected to the vehicle chassis, front end moduleor the fascia of the vehicle.

Referring now to FIG. 2A, an assembled active grille shutter arrangement10 is shown having the having the specific valves 34 are shown. Theplurality of vanes 34 include a driving vane 84 connected to the motorand the other of the plurality of vanes are driven vanes 86 that aredriven by a link bar 88 connected to the driving vane 84. FIG. 2A showstwo driving vanes 84, located on opposite sides of the motor housing 36which allows for the two apertures of the modular frame to be opened andclosed independently of each other depending on the type of motor used.

Referring now to FIGS. 9-14 several alternate embodiments of the modularframe of the active grille shutter system 10 are shown and described. Ineach of these various embodiments the modular frame has a differentshape, and in other embodiments has differently shaped primary framepieces and secondary frame pieces, which are assembled together to formthe modular frame of the active grille shutter arrangement. Inparticular FIG. 9 shows an alternate embodiment of a modular frame 112having a primary frame piece 102 that is a one piece having the shape ofa capital letter “I” or capital letter “H”. The primary frame piece 102defines a width and height of an aperture 104 of the modular frame 112.The primary frame piece 102 in the present embodiment of the inventionis a single piece and further includes a motor housing 106, upper frameportion 108 and lower frame portion 110. The motor housing 106 extendsbetween the upper frame portion 108 and the lower frame portion 110 anddivides the aperture 104 in half. The modular frame 112 further includesa plurality of secondary frame pieces 127, 127 that include a first endcap 126 and second end cap 128. The first end cap 126 and second end cap128 are connectable to both the upper frame portion 108 and lower frameportion 110. The first end cap 126 connects to a first end 116 of theupper frame portion 108 and a first end 118 of the lower frame portion110. The second end cap 128 connects to a second end 120 of the upperframe portion 108 and a second end 122 of the lower frame portion 110.The manner in which the connection between the first end cap 112 andsecond end cap 114 with the primary frame piece is shown and describedabove with respect to FIGS. 5 and 6. The present embodiment of theinvention allows for the modular frame 112 to be formed from a fewernumber of pieces than the embodiments shown and described in FIG. 4.

Referring now to FIG. 11 an alternate embodiment of a modular frame 212is shown. The elements of a modular frame 112 are similar or identicalto those shown and described with respect to FIG. 9 above, thereforesimilar elements have been labeled using the same reference numerals. Inthe present embodiment of the invention a primary frame piece 202includes bridge elements 204, 206 that are formed as part of the primaryframe piece 202 or snapped onto the primary frame piece 202 in order tostabilize and prevent warping of the primary frame piece 202. Thestabilization and warping can occur during the formation of the primaryframe piece 202, which is typically formed from molten polymer, or thewarpage can result during transport, prior to assembly of the modularframe 200. The first end cap 112 and second end cap 114 are connected tothe primary frame piece 202 in the same manner as described above. Thebridge elements 204, 206 are formed onto the primary frame piece 202during molding or they may be connected to the primary frame piece 202after formation. The bridge elements can either stay in place uponconnection of the secondary frame pieces, such as the first end cap 126or second end cap 128 or they can be removed after connection of thefirst end cap 126 or second end cap 128.

Referring now to FIG. 10 another alternate embodiment of a modular frame312 is shown for an active grille shutter arrangement 300. In thisembodiment of the invention there is a primary frame piece 302 withthree sides including an upper frame portion 318, lower frame portion310 and a motor housing 306 that houses the motor for driving aplurality of vanes 326 in a manner similar to the embodiments describedabove. The motor housing 306 extends between the upper frame portion 318and the lower frame portion 310. The upper frame portion has an end 316and the lower frame portion has an end 320 that a secondary frame piece322, that is an end cap 324 similar to the first end cap and second endcap in the previous embodiments connects to form an aperture 304. Inthis embodiment of the invention the motor housing does not extendacross the aperture 304 of the modular frame 312. Vanes 326 extendacross the aperture 304 and rotatably connect to the motor housing 306and the secondary frame 322. The modular frame 312 in the presentembodiment of the invention is used in active grille shutterarrangements where it is desirable to not divide the aperture 304 inhalf using a motor housing. Also the vanes 326 are controlled by a motorand link bar which are shown and described in FIG. 2 above.

Referring now to FIG. 12 an alternate embodiment of a modular frame 512having a primary frame piece 502 that is one piece having the shape of acapital letter “T”. The primary frame piece 502 defines a width andheight of an aperture 504, 504′ of the modular frame 512. The primaryframe piece 502 in the present embodiment of the invention is a singlepiece and further includes a motor housing 506 and upper frame portion508. There is a secondary frame piece 509 having the shape of a capitalletter “U” and is a single piece having a lower frame portion 506 andupwardly extending first end portion 508 and second end portion 510. Thefirst end portion 508 and second end portion 510 each have a receivingend joint 513, 514 that face upward toward the primary frame piece 502.The upper frame portion 508 has downwardly facing post 516, 518 that arereceived by a respective receiving end joint 513, 514. The motor housing506 has a lower motor housing connection member 522 and connection point520 formed on the lower frame portion 506 that connects the motorhousing 506 to the secondary frame piece 509. The motor housing 506extends between the upper frame portion 508 and lower frame portion 506and defines the aperture 504,504′. The connection between eachdownwardly facing post 516, 518 and the receiving end joint 513, 514 andthe lower motor housing connection member 522 and connection point 520are not limited to any particular configuration but can be the types ofconnections shown and described in FIGS. 5, 6 and 7. The modular frame512 in the present invention can be assembled by vertically snapping theprimary frame piece 502 and the secondary frame piece 509 together.

FIG. 13 depicts an additional alternate embodiment of the modular frame512 shown in FIG. 12. In this embodiment a modular frame 612 a primaryframe piece 602 that is a one piece having the shape of a capital letter“T”. The primary frame piece 602 defines a width and height of anaperture 604 of the modular frame 612. The primary frame piece 602 inthe present embodiment of the invention is a single piece and furtherincludes a motor housing 606 and upper frame portion 608. There is asecondary frame piece 609 having the shape of a capital letter “U” andis a single piece having a lower frame portion 606 and upwardlyextending first end portion 608 and second end portion 610. The firstend portion 608 and second end portion 610 each have a receiving endjoint 613, 614 that face perpendicular to the plane of the aperture 604formed in the modular frame 612. The upper frame portion 608 has a post616, 618 that also face in a direction perpendicular to the aperture 604and are received by a respective receiving end joint 613, 614. The motorhousing 606 has a lower motor housing connection member 622 andconnection point 620 formed on the lower frame portion 606 that connectsthe motor housing 606 to the secondary frame piece 609. The motorhousing 606 extends between the upper frame portion 608 and lower frameportion 606 and divides the aperture 604 in half. The connection betweeneach post 616, 618 and the receiving end joint 513, 514 and the lowermotor housing connection member 622 and connection point 620 are notlimited to any particular configuration but can be the types ofconnections shown and described in FIGS. 5, 6 and 7. The modular frame612 in the present invention is assembled by horizontally snapping theprimary frame piece 602 and the secondary frame piece 609 together bymoving the piece perpendicular to the plane of the aperture 504 formedby the modular frame 512.

Referring to FIG. 14 an alternate embodiment of a modular frame 412 isshown. The modular frame 412 has a primary frame piece 403 that is asingle piece having a generally rectangular shape that defines anaperture 418,418′. While a rectangular shape is shown, it is within thescope of this invention for the modular frame 412 to have a differentshape, such as but not limited to a square, circle, trapezoid orvirtually any other type of shape. The primary frame piece 403 has anupper frame portion 402, lower frame portion 404. There is a first endportion 408 extending between the upper frame portion 402 and lowerframe portion 404 at one end and a second end portion 406 extendingbetween the upper frame portion 402 and lower frame portion 404 at asecond end. A secondary frame piece 409, which is a motor housing 410used to house an actuator for the active grille shutter system connectsto the upper frame portion 402 and at the lower frame portion 404. Themotor housing 410 has a lower motor housing connection member 416 thatconnects to a connection point 417 formed on the lower frame portion 404and an upper motor housing connection member 415 that connects to aconnection point 414 formed on the upper frame portion 402. Theconnections for the motor housing 410 can take any form but include allof the types of connections shown and described in FIG. 7.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. An active grille shutter arrangement having anmodular frame comprising: a primary frame piece defining a width andheight of an aperture of the modular frame: at least one secondary framepiece connectable to the primary frame piece, wherein the primary framepiece and the at least one secondary frame piece form the modular framehaving at least one aperture capable of allowing air to pass through themodular frame; at least one connection joint between the primary framepiece and the at least one secondary frame, wherein the at least oneconnection joint each include an interlocking dovetail joint securedwith a tab and boss; and a plurality of vanes rotatably positionedbetween the at least one primary frame piece and the at least onesecondary frame.
 2. The active grille shutter arrangement of claim 1further comprising: a motor housing forming part of the primary framepiece or the at least one secondary frame piece; and a motor connectedto the motor housing, wherein the motor is connected to the plurality ofvanes to cause the plurality of vanes to rotate between an openposition, closed position and one or more intermediate positionsrelative to the aperture of the modular frame.
 3. The active grilleshutter arrangement of claim 2, wherein the motor housing extends acrossthe aperture of the modular frame, dividing the aperture into twosections.
 4. The active grille shutter arrangement of claim 2, whereinthe motor housing does not extend across the aperture of the modularframe.
 5. The active grille shutter arrangement of claim 1 furthercomprising: one of the plurality of vanes is a driving vane connected toa motor and all of the other plurality of vanes are connected to thedriving vane by a linkage mechanism for rotating all the plurality ofvanes in response to the motor rotating the driving vane.
 6. The activegrille shutter arrangement of claim 1 further comprising: wherein eachone of the plurality of vanes has two ends with barrels formed on eachof the two and ends; and holes formed on the primary frame piece and theat least one secondary frame piece to rotatably receive one of saidbarrels of one of said plurality of vanes.
 7. The active grille shutterarrangement of claim 1 further comprising: one or more bridges on theprimary frame piece for stabilizing the primary frame piece frameportion prior to connection of the at least one secondary frame piece.8. An active grille shutter arrangement having an modular framecomprising: a primary frame piece defining a width and height of anaperture of the modular frame: at least one secondary frame piececonnectable to the primary frame piece, wherein the primary frame pieceand the at least one secondary frame piece form the modular frame havingat least one aperture capable of allowing air to pass through themodular frame; and a plurality of vanes rotatably positioned between theat least one primary frame piece and the at least one secondary frame;at least one connection joint between the primary frame piece and the atleast one secondary frame piece; an end cap snap tab and snap postconnection located at each of the least one connection joint between theprimary frame piece and the at least secondary frame piece.
 9. Theactive grille shutter arrangement of claim 8 further comprising: a motorhousing forming part of the primary frame piece or the at least onesecondary frame piece; and a motor connected to the motor housing,wherein the motor is connected to the plurality of vanes to cause theplurality of vanes to rotate between an open position, closed positionand one or more intermediate positions relative to the aperture of themodular frame.
 10. The active grille shutter arrangement of claim 9,wherein the motor housing extends across the aperture of the modularframe, dividing the aperture into two sections.
 11. The active grilleshutter arrangement of claim 9, wherein the motor housing does notextend across the aperture of the modular frame.
 12. The active grilleshutter arrangement of claim 8 further comprising one of the pluralityof vanes is a driving vane connected to a motor and all of the otherplurality of vanes are connected to the driving vane by a linkagemechanism for rotating all the plurality of vanes in response to themotor rotating the driving vane.
 13. The active grille shutterarrangement of claim 8 further comprising: wherein each one of theplurality of vanes has two ends with barrels formed on each of the twoand ends; and holes formed on the primary frame piece and the at leastone secondary frame piece to rotatably receive one of said barrels ofone of said plurality of vanes.
 14. The active grille shutterarrangement of claim 8 further comprising: one or more bridges on theprimary frame piece for stabilizing the primary frame piece frameportion prior to connection of the at least one secondary frame piece.15. An active grille shutter arrangement having an modular framecomprising: a primary frame piece defining a width and height of one ormore apertures of the modular frame, wherein the primary frame piece hasan upper frame portion having a first end and a second end, a lowerframe portion having a first end and a second end and a motor housingextending between the upper frame portion and the lower frame portion; aplurality of secondary frame pieces including a first end cap,connectable to the respective first end of the upper frame portion andfirst end of the lower frame portion by an upper bar end joint formed onthe first end of the upper frame portion and a lower bar end jointformed on the first end of the lower frame portion, and a second end capof the plurality of secondary frame pieces connectable to both thesecond end of the upper frame portion and the second end of the lowerframe portion by an upper bar end joint formed on the second end of theupper frame portion and a lower bar end joint formed on the second endof the lower frame portion; the modular frame of the active grillershutter arrangement formed by the connection of the primary frame pieceand the secondary frame piece, wherein the modular frame defines the oneor more apertures; a plurality of vanes rotatably positioned between thefirst end cap and the second end cap for controlling the amount of airflowing through the one or more apertures formed by the modular frame;and wherein the motor housing of the primary frame piece extends betweenthe upper frame portion and the lower frame portion.
 16. The activegrille shutter arrangement of claim 15 further comprising: a motorconnected to the motor housing, wherein the motor is connected to theplurality of vanes to cause the plurality of vanes to rotate between anopen position, closed position and one or more intermediate positionsrelative to the aperture of the modular frame.
 17. The active grilleshutter arrangement of claim 16, wherein the motor housing extendsacross the aperture of the modular frame, dividing the aperture into twosections.
 18. The active grille shutter arrangement of claim 16, whereinthe motor housing does not extend across the aperture of the modularframe, dividing the aperture into two sections.
 19. The active grilleshutter arrangement of claim 15 further comprising: one of the pluralityof vanes is a driving vane connected to the motor and all of the otherplurality of vanes are connected to the driving vane by a linkagemechanism for rotating all the plurality of vanes in response to themotor rotating the driving vane.
 20. The active grille shutterarrangement of claim 15 wherein the upper bar end joint formed on thefirst end of the upper frame portion, the lower bar end joint formed onthe first end of the lower frame portion, the upper bar end joint formedon the second end of the upper frame portion and the lower bar end jointformed on the second end of the lower frame portion each include aninterlocking dovetail joint secured with a tab and boss.
 21. The activegrille shutter arrangement of claim 15 wherein the upper bar end jointformed on the first end of the upper frame portion, the lower bar endjoint formed on the first end of the lower frame portion, the upper barend joint formed on the second end of the upper frame portion and thelower bar end joint formed on the second end of the lower frame portioneach include an end cap snap tab and snap post connection located ateach of the least one connection point between the primary frame and thesecondary frame.
 22. The active grille shutter arrangement of claim 15further comprising: wherein each one of the plurality of vanes has twoends with barrels formed on each of the two and ends; and holes formedon the primary frame piece and secondary frame to rotatably receive oneof said barrels of one of said plurality of vanes.
 23. The active grilleshutter arrangement of claim 15, wherein the motor housing has an upperend connected to an upper frame center joint formed on the upper frameportion between the first end and the second end of the upper frameportion and a lower end of the motor housing connected to the lowerframe portion at a lower frame center joint formed on the lower frameportion between the first end and the second end of the lower frameportion.
 24. The active grille shutter arrangement of claim 23 whereinthe connection between the motor housing at the lower frame center jointand the upper frame center joint are each an interlocking dovetail jointsecured with a tab and boss connected together with a fastener when thetab and boss are aligned.
 25. The active grille shutter arrangement ofclaim 15 further comprising a lower end of the motor housing connectedto the lower frame portion at a lower frame center joint formed on thelower frame portion between the first end and the second end of thelower frame portion.
 26. The active grille shutter arrangement of claim25 wherein the connection between the motor housing at the lower framecenter joint is an interlocking dovetail joint secured with a tab andboss connected together with a fastener when the tab and boss arealigned.
 27. The active grille shutter arrangement of claim 15 furthercomprising one or more bridges extending between the upper frame portionand the lower frame portion for stabilizing the upper frame portion andlower frame portion prior to connection of the plurality of secondaryframe pieces.
 28. A modular frame kit including interchangeable parts ofvarying sizes used to create different modular frames comprising: one ofa first modular frame, second modular frame and third modular frame eachhaving a different height and width formed from the modular frame kitcomprising: one selected upper frame portion selected from a groupcomprising a first upper frame portion, a second upper frame and a thirdupper frame portion each having different widths; one selected lowerframe portion selected from a group comprising a first lower frameportion, a second lower frame and a third lower frame portion eachhaving different widths; one selected motor housing selected from agroup comprising a first motor, second motor housing and third motorhousing each having different heights; one selected set of end capsselected from a group comprising a first set of two end caps, second setof two end caps and third set of two end caps each having differentheights; and wherein each one of the one selected set of end caps isconnected to respective opposing ends of the one selected upper frameportion and one selected lower frame portion forming a rectangularframe, and the one selected motor housing connected between the oneselected upper frame portion and the one selected lower frame portion.